Absorbent product containing absorbent articles each having different graphic

ABSTRACT

In one aspect, the invention is directed to an absorbent product. The absorbent product includes a package and at least n absorbent articles contained in the package (n is greater than 10). Each of the absorbent articles has a body contacting surface and a garment contacting surface opposing the body contacting surface. Each of the absorbent articles includes a component material disposed between the body contacting surface and the garment contacting surface. The component material has a printed graphic which is seen through either the body contacting surface or the garment contacting surface. The n graphics of the n absorbent articles are different from each other, and preferably have a predetermined association. In another aspect, the invention is directed to a method of printing a graphic on a sheet material which will become a component material for the absorbent articles. In an yet another aspect, the invention is directed to a method of producing the absorbent product including the package and the n absorbent articles contained in the package.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. ProvisionalApplication No. 60/441,432, filed on Jan, 21, 2003.

FIELD OF THE INVENTION

[0002] The present invention relates to absorbent articles. Moreparticularly, the present invention relates to an absorbent productwhich contains absorbent articles each having a different graphic.

BACKGROUND

[0003] Infants and other incontinent individuals wear a disposablearticle such as a disposable diaper to receive and contain urine andother body exudates. Absorbent articles function to contain thedischarged materials and to isolate these materials from the body of thewearer and from the wearer's garments and bed clothing. It is generallyknown in the art that disposable absorbent articles have many differentbasic designs. Examples of such disposable articles include disposablediapers (for baby and adult) including pull-on diapers and trainingpants, disposable absorbent pads including sanitary napkins, pantilinersand incontinent pads, disposable underwears, and disposable panties formenstrual use.

[0004] The exterior of these disposable absorbent articles is coveredwith a flexible, liquid impervious member to prevent a leakage ofabsorbed liquids from the disposable absorbent articles. Such a liquidimpervious member is generally referred to as a backsheet, and is oftenconstructed from a liquid impervious material such as a polyethylenefilm, and other outer cover material such as a nonwoven material (ifdesired). The backsheet constitutes the garment contacting surface ofthe absorbent articles.

[0005] It is also known that the garment contacting surface of theabsorbent articles often has a printed graphic(s) to get users' orconsumers' positive attention not only in use but also in the market.Such a graphic(s) is typically printed on either a landing zone materialor a backsheet material. (The landing zone material is the anchor zonemember for the tape fastening system in a tape type diaper.) Printingthese graphics on the garment contacting surface of disposable absorbentarticles has been becoming popular among consumers due to theirentertainment functions.

[0006] Those graphics are typically printed by using conventionalprinting techniques such as the gravure and flexography technologieswhich employ a printing plate to print the graphic on a sheet material(e.g., a backsheet material, a landing zone material, and a fasteningtape material). The printing plate has ink images for graphics to beprinted. The printing plate is typically mounted on a printing cylinderin a printing process. In the printing process, when the cylinderrotates, the printing plate contacts the sheet material to transfer theink images to the sheet material thereby printing the graphics thereon.

[0007] The number of the ink images which can be prepared in theprinting plate depends on the sizes of the ink images (or the graphicsto be printed), the printing plate and the cylinder. In general, sincethe size of the landing zone member is not large, the size of the inkimages prepared in the printing plate tends to be small. On the otherhand, since the size of the backsheet is relatively large (i.e., clearlylarger than the landing zone member), the size of the repeated inkimages tends to be large. This means that the total area of the printingplate is occupied by a small number of ink images. As a result, thenumber of the graphics to be printed is limited in particular for arelatively large component material of disposable absorbent articlessuch as a backsheet material.

[0008] Because of the above reasons, the variety of the graphics printedon conventional disposable absorbent articles is limited in one package.For example, the maximum number in the variety of the graphics printedon conventional disposable absorbent articles which are packed in onepackage is 10.

[0009] Thus, it is understood that this limitation results in preventingusers or consumers from enjoying more variety of graphics in thedisposable absorbent articles packed or contained in one package. Inaddition, this limitation also limits the function of the graphicswithin a limited area, i.e., a mere entertainment for enjoying thevariety within the limited number. Further, this limitation has become arestriction to illustrate a complete theme which is believed to helpchildren's education or development.

[0010] Hence, there is a need for an absorbent product that can providean unlimited number of graphics printed on absorbent articles. There isalso a need for a printing method for a component material of absorbentarticles that can provide an unlimited number of graphics printed on thecomponent material in one package. There is further a need for a packingmethod of absorbent articles having an unlimited number of graphicsprinted thereon in one package.

SUMMARY

[0011] In one aspect, the invention is directed to an absorbent product.The absorbent product includes a package and at least n absorbentarticles contained in the package (n is greater than 10). Each of theabsorbent articles has a body contacting surface and a garmentcontacting surface opposing the body contacting surface. Each of theabsorbent articles includes a component material disposed between thebody contacting surface and the garment contacting surface. Thecomponent material has a printed graphic which is seen through eitherthe body contacting surface or the garment contacting surface. The ngraphics of the n absorbent articles are different from each other, andpreferably have a predetermined association.

[0012] In another aspect, the invention is directed to a method ofprinting a graphic on a which will become a component material forabsorbent articles. The method includes the steps of: (a) storinggraphic data in a graphic memory for printing n graphics, n beinggreater than 2; (b) selecting graphic data stored in the graphic memory;(c) printing a graphic based on the selected graphic data by an ink jeton the sheet material; and (d) repeating the steps (b) and (c) so thatthe n graphics are printed on the sheet material.

[0013] In an yet another aspect, the invention is directed to a methodof producing an absorbent product including a package and at least nabsorbent articles contained in the package (n is greater than 10). Themethod includes the steps of: (a) supplying a sheet material having aplurality of printing frames sequentially disposed along the machinedirection (each printing frame including n graphics printed sequentiallyin the machine direction); (b) incorporating other component materialswith the sheet material to form n absorbent articles in the machinedirection (each absorbent article having a corresponding graphic of then graphics); (c) detecting the printing frame in the sheet material; (d)transporting the absorbent articles which are within the detectedprinting frame; and (e) packing the transported absorbent articles intoone package.

[0014] The foregoing answers the need for an absorbent product that canprovide an unlimited number of graphics printed on absorbent articles.The foregoing also answers the need for a printing method for acomponent material of absorbent articles that can provide an unlimitednumber of graphics printed on the component material.

[0015] These and other features, aspects, and advantages of the presentinvention will become evident to those skilled in the art from readingof the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] While the specification concludes with claims particularlypointing out and distinctly claiming the subject matter which isregarded as forming the present invention, it is believed that theinvention will be better understood from the following description whichis taken in conjunction with the accompanying drawings in which:

[0017]FIG. 1 is a perspective view of an absorbent product which is onepreferred embodiment of the present invention;

[0018]FIG. 2 is a perspective view of a pull-on diaper which istypically contained in the absorbent product shown in FIG. 1;

[0019]FIG. 3 is a partially cut-away plan view of the pull-on diaper ofFIG. 2, which is viewed from the garment contacting surface;

[0020]FIG. 4 is a simplified block diagram of a printing andmanufacturing apparatus for disposable absorbent articles;

[0021]FIG. 5 is a flow chart which shows a process for printing ngraphics on a sheet material; and

[0022]FIG. 6 is a flow chart which shows a process for packing nabsorbent articles into one package.

DETAILED DESCRIPTION

[0023] All cited references are incorporated herein by reference intheir entireties. Citation of any reference is not an admissionregarding any determination as to its availability as prior art to theclaimed invention.

[0024] Herein, “comprise”, “include” and “contain” mean that otherelements and/or other steps which do not affect the end result can beadded. Each of these terms encompasses the terms “consisting of” and“consisting essentially of”.

[0025] Herein, “absorbent article” refers to articles which are worn inthe crotch region of a garment and absorb/contain body exudates ordischarges. The absorbent article is intended to include diapers (forbaby and adult) including tape type diapers, pull-on diapers andtraining pants; absorbent pads including sanitary napkins, pantilinersand incontinent pads; underwears, and panties for menstrual use.

[0026] Herein, “disposable” refers to articles which are intended to bediscarded after a single use, composted, or otherwise disposed of in anenvironmentally compatible manner. (That is, they are not intended to belaundered or otherwise restored or reused as an absorbent article.)

[0027] Herein, “joined” encompasses configurations in which an elementis directly secured to another element by affixing the element directlyto the other element; configurations in which the element is indirectlysecured to the other element by affixing the element to intermediatemember(s) which in turn are affixed to the other element; andconfigurations in which one element is integral with another element,i.e., one element is essentially part of the other element.

[0028] Herein, “body facing surface” refers to surfaces of absorbentarticles and/or their component materials which face the body of thewearer, while “garment facing surface” refers to the opposite surfacesof the absorbent articles and/or their component materials that faceaway from the wearer when the absorbent articles are worn. Absorbentarticles and components thereof, including the topsheet, backsheet,absorbent core, and any individual materials of their components, have abody facing surface and a garment facing surface.

[0029] Herein, “body contacting surface” refers to the surface ofabsorbent articles which primarily contacts the body of the wearer,while “garment contacting surface” refers to the surface of theabsorbent articles that primarily contacts the wearer's garment when theabsorbent articles are worn. Typically, the body contacting surface isthe body facing surface of a topsheet, while the garment contactingsurface is the garment facing surface of a backsheet.

[0030] Herein, “graphic” refers to images or designs that areconstituted by a figure (i.e., a line(s)), a symbol or character, acolor difference or transition of at least two colors, or the like. Thegraphic preferably has an aesthetic image or design that can providecertain benefit(s) when the absorbent article of the invention is lookedor viewed by users or consumers. A variety of graphics can be used inthe absorbent articles of the invention. Such graphics will be describedin detail hereinafter.

[0031] A. Absorbent Product

[0032]FIG. 1 is a perspective view of an absorbent product 500 which isone preferred embodiment of the present invention. The absorbent product500 of the invention includes a package 100 and at least n absorbentarticles 201-20 n which are stacked and contained in the package 100 (nis greater than 10). Each of the absorbent articles 201-20 n has a bodycontacting surface 22 and a garment contacting surface 24 opposing thebody contacting surface 22. Each of the absorbent articles 201-20 nincludes a plurality of component materials (e.g., a backsheet material,a topsheet material, an acquisition layer material, an absorbent corematerial, and a landing zone material) disposed between the bodycontacting surface and the garment contacting surface. The plurality ofcomponent materials constitute each absorbent article 201-20 n.

[0033] Each of the component materials can be any member whichconstitutes at least a part of the absorbent article. At least one ofthe component materials is selected from the group consisting of abacksheet, a topsheet, an acquisition layer, an absorbent core, and alanding zone for waist-fastening means (not shown in FIG. 1). At leastone of the component materials has a graphic(s) printed on its garmentfacing surface or body facing surface. (Hereinafter such a componentmaterial is referred to as “graphic component material”.)

[0034] In the embodiment shown in FIG. 1, the graphic component materialis a backsheet 52. The graphic component material (i.e., the backsheet52) has a printed graphics G1-Gn which is seen through either the bodycontacting surface 22 or the garment contacting surface 24. (In theembodiment of FIG. 1, the graphics G1-Gn are seen at least through thegarment contacting surface 24.) The graphics G1-Gn of the n absorbentarticles are different from each other.

[0035] In preferred embodiments, the graphics G1-Gn are different fromeach other in terms of graphic design. Herein, “different in terms ofgraphic design” means that graphics are intended to be different whenthey are looked by users or consumers with their normal attentions.Thus, two graphics having a graphic difference(s) which areunintentionally caused due to a problem(s) or an error(s) in amanufacture process, for example, are not different from each other interms of graphic design. The graphic design is determined by, forexample, the color(s) used in the graphic, the sizes of the graphic (orits components), the positions of the graphic (or its components), themovements of the graphic (or its components), the geometrical shapes ofthe graphic (or its components), the number of colors in the graphic,the variations of the color combinations in the graphic, the number ofgraphics printed, the disappearance of color(s) in the graphic, and thecontents of text messages in the graphic.

[0036] It should be noted that although the package 100 contains theabsorbent articles 201-20 n which have the graphics G1-Gn different fromeach other, the package 100 can further contain, if desired, one or moreadditional absorbent article(s) (not shown in FIG. 1) which has agraphic that is same as one the other graphics in the package 100. Inother words, the absorbent product 500 of the invention includes atleast n absorbent articles 201-20 n which have the graphics G1-Gndifferent from each other, and can include an additional absorbentarticle(s) each having a same graphic(s).

[0037] The graphics G1-Gn can be printed on either the body facingsurface or the garment facing surface of the component material. In apreferred embodiment, the graphics G1-Gn are printed on the garmentfacing surface of a backsheet material so that the graphics G1-Gn can beseen through the garment contacting surface 24 of the absorbent articles201-20 n, as shown in FIG. 1. In an alternative preferred embodiment,the graphics G1-Gn are printed on the body facing surface of thebacksheet material so that the graphics G1-Gn can be seen through boththe garment and body contacting surfaces of the absorbent articles201-20 n, e.g., the backsheet material and the topsheet material.

[0038] The backsheet preferably includes two (or more) layers ofmaterial(s). For example, the backsheet includes a laminate whichincludes a liquid impervious film and a nonwoven outer cover materialwhich is joined to the garment facing surface of the liquid imperviousfilm. The graphics G1-Gn can be printed on either the garment facingsurface or the body facing surface of the liquid impervious film.Alternatively, the graphics G1-Gn can be printed on either the garmentfacing surface or the body facing surface of the nonwoven outer covermaterial. In a preferred embodiment, the graphics G1-Gn are printed onthe body facing surface of the nonwoven outer cover material.

[0039] The position of the graphics G1-Gn is preferably registeredwithin a predetermined area of the absorbent articles 201-20 n such thateach of the graphics G1-Gn appears on the intended position (or thepredetermined area) in each absorbent articles 201-20 n withoutunintentional variation. In the embodiment shown in FIG. 1, the graphicsG1-Gn are registered in the rear region of the absorbent articles 201-20n. A preferred registration method is disclosed in U.S. Pat. No.5,766,389 issued to Brandon et al. on Jun. 16, 1998.

[0040] The package 100 can be formed by any material and can take anystructure known in the art. For example, the package 100 can be a cartonwhich is formed by a cardboard material. In the embodiment shown in FIG.1, the package 100 is a flexible bag which is formed by a thin filmmaterial. Such a thin film material can be made of a paper, a plastic, arecyclable material, or a laminate material comprised of two or more ofthese materials. In a preferred embodiment, the package 100 is a polybag which is formed by a polyethylene film.

[0041] The package 100 includes a front panel 110, a rear panel 120 (notshown in FIG. 1) opposed to the front panel 110, side panels 130 whichconnects the front and rear panels 110 and 120, a top gusset panel 140which connects the front, rear, and side panels 110, 120 and 130, and abottom panel 150 (not shown in FIG. 1) opposed to the top panel 140.Each of the front and rear panels 110 and 120, the side panels 130 andthe bottom panels 150 are substantially planar as shown in FIG. 1. Thepackage 100 preferably has at least one transparent window 160 whichshows at least one of the graphics G1-Gn through the window 160 to getusers' or consumers' attention in the market place. There is nolimitation to the number of the window(s) 160 to be formed in thepackage 100. Preferably, in total from one to five transparent windowsare formed in the front, rear, and side panels 110, 120 and 130. In theembodiment shown in FIG. 1, the side panel 130 has the transparentwindow 160 which shows the graphic G1 printed on the absorbent article201.

[0042] B. Graphics

[0043] The graphics G1-Gn of the absorbent articles 201-20 n preferablyhave a predetermined association. Herein, “association” refers to arelationship which can conceptually bond a plurality of graphics. Thepredetermined association is formed by the graphic designs of the ngraphics. The predetermined association preferably includes apredetermined order and/or a common theme.

[0044] In a preferred embodiment, the predetermined association includesa predetermined order, and the n absorbent articles are stacked in thepackage in accordance with the predetermined order. The predeterminedorder preferably includes an order illustrating story, an order fordaily activity, an order for educational training, a sequentialindication means, an order of usage instruction, an order illustratingchild care tips, and an order of sales promotion. More specifically,each absorbent article carries one step (or stage) in a predeterminedorder in the graphic, and the predetermined order is completed by the ngraphics of the n absorbent articles.

[0045] The story preferably includes a children's story and a cartoonstory such as Aesop's Fables, Doraemon cartoon, Sesame street, and thelike.

[0046] The daily activity includes, for example, eating foods, wearing(or changing) a cloth, taking a bath, a toilet activity, making anobject, cooking a food, sleeping, and growing a plant. For example, whenchanging clothes, the absorbent article 201 has a graphic G1 which showsthe first step of changing clothes (e.g., taking off a pair of pajamas),the absorbent article 202 has a graphic G2 which shows the second step(e.g., taking off a used underwear), the absorbent article 203 has agraphic G3 which shows the third step (e.g., putting on a cleanunderwear), and the like. If desired, the daily activity is showntogether with a preferred time for such activities in the graphics G1-Gn(e.g., 8:00 PM for sleeping).

[0047] The educational training preferably includes a puzzle or quiz onmathematics, characters (e.g., numbers and letters) which are decoratedor undecorated, shapes of goods, combinations of colors, and a patternrecognition for intelligence development.

[0048] The sequential indication means includes a sequential symbol.Preferably, the sequential symbol indicates the number of the remainingabsorbent articles in the package when the absorbent articles areconsumed. Any sequential symbol including numbers (e.g., 1-60) andletters (e.g., A-Z) can be used. Such numbers and letters can also beused as an educational tool for kids when they are appropriately used byusers.

[0049] The usage instruction can includes any information for users toeffectively use absorbent articles.

[0050] The child care tips can includes any information for users (orcare givers) to effectively take care of babies or children.

[0051] The sales promotion can includes any information for effectivelyadvertising the absorbent articles to consumers.

[0052] In an alternative preferred embodiment, the predeterminedassociation includes a common theme, and the n absorbent articles arestacked in the package in a randomly selected order. The common themecan be any theme which is consistently expressed in the n graphics. Thecommon theme preferably includes cartoon characters (e.g., one Sesamestreet character is doing different activities such as playing, eating,taking a bath, and the like, or a plurality of different sesame streetcharacters are doing same/different activities), transportation means(e.g., cars, trains, ship, planes, etc.), animals (e.g., dogs, cats,rabbits, etc.), fruits (e.g., bananas, oranges, apples, etc.),vegetables (e.g., carrots, pumpkins, potatoes, etc.), plants (e.g.,tulips, morning glories, roses, etc.), and seasonal themes (e.g.,snowmen, etc.).

[0053] C. Absorbent Article

[0054]FIG. 2 is a perspective view of a pull-on diaper 20 (as oneexample of disposable absorbent articles) which is preferably containedin the package 100 shown in FIG. 1. Referring to FIG. 2, the pull-ondiaper 20 has a body contacting surface 22, and a garment contactingsurface 24 opposed to the body contacting surface 22. The pull-on diaper20 shown in FIG. 2 is viewed from the garment contacting surface 24. Thepull-on diaper 20 has a waist opening 63 and two leg openings 62. Thepull-on diaper 20 has a graphic G which is printed in the rear regionand can be seen through the garment contacting surface 24.

[0055]FIG. 3 is a partially cut-away plan view of the pull-on diaper 20of FIG. 2, which is viewed from the garment contacting surface 24. InFIG. 3, the pull-on diaper 20 is shown in its uncontracted state, priorto ear (or side) panels being joined together. The pull-on diaper 20includes three primary components, i.e., a liquid pervious topsheet 54,a liquid impervious backsheet 52, and an absorbent core 66 disposedbetween the topsheet 30 and the backsheet 52. The outermost surface ofthe backsheet 52 forms the garment contacting surface 24 of the pull-ondiaper 20, while the innermost surface of the topsheet 30 forms the bodycontacting surface 22 (not shown in FIG. 3) of the pull-on diaper 20.

[0056] The backsheet 52 can be formed by only one sheet (or layer)material such as a breathable (or microporous) film material or anon-breathable (or non-microporous) film material. Alternatively, thebacksheet 52 can be formed by two (or more) sheet (or layer) materialswhich preferably includes a non-breathable (or breathable if desired)film material and a nonwoven outer cover material. In the preferredembodiment shown in FIG. 3, the backsheet 52 is formed by a laminate oftwo sheet (or layer) materials joined together, i.e., the backsheet 52includes a non-breathable film material 53 and a nonwoven material 55which is joined to the garment surface of the film material 53 toprovide a cloth-like and/or garment-like feel.

[0057] The graphic G can be printed on any surface of the componentmaterial(s) of the backsheet 52. Specifically, the graphic G can beprinted on any of the garment facing surfaces and the body facingsurfaces of the film material 53 and the nonwoven material 55.Preferably, the graphic G is printed on the garment facing surface ofthe film material 53. This is preferred because the graphic G can becovered (or protected) by the nonwoven material 55. The graphic G can beseen through the nonwoven material 55.

[0058] The nonwoven material 55 is joined with at least a portion of thegarment facing surface of the film material 53 to form a laminatestructure. The nonwoven sheet 55 preferably covers all or substantiallyall of the garment facing surface of the film material 53 to provide thediaper with a cloth-like look and feel, although it can cover only adiscrete predetermined portion(s) if desired.

[0059] The microporous film material 53 may comprise any known materialbeing moisture pervious and liquid impervious. For example, themicroporous film material 53 may comprise a breathable microporous filmcomposed of a thermoplastic resin and inorganic fillers dispersed in thethermoplastic resin. Suitable thermoplastic polymers include polyolefinssuch as polyethylenes, including liner low density polyethylene (LLDPE),low density polyethylene (LDPE), ultra low density polyethylene (ULDPE),high density polyethylene (HDPE), or polypropylene and blends thereofwith the above and other materials. A preferred microporous filmmaterial is a breathable microporous film material of 100% polyethyelene(25 gsm ), which is available from Mitsui Chemical, Nagoya, Japan, underCode No. Espoir-N-PG-P3.

[0060] The nonwoven material 55 may comprise natural fibers (e.g. cottonor wood fibers), or may comprise fibers of polyolefins such aspolyethylene and polypropylene, polyester, or any combination of suchfibers. Polyolefin fibers are preferable. Further, the nonwoven may becarded, spunbond, meltblown or air-through bonded or have any othercharacteristic or be manufactured in any manner known in the art. Apreferred nonwoven material is a spunbonded nonwoven formed by 100%polypropylene fibers (20 gsm), which is available from Mitsui ChemicalIndustry, Japan, under Code No. PC-0220.

[0061] The absorbent core 66 can includes any absorbent materials knownin the art. Such absorbent materials are generally compressible,conformable, non-irritating to the wearer's skin, and capable ofabsorbing and retaining liquids such as urine and other certain bodyexudates. The absorbent core 66 may be manufactured in a wide variety ofsizes and shapes (e.g., rectangular, hourglass, “T”-shaped, asymmetric,etc.) and from a wide variety of liquid-absorbent materials commonlyused in disposable diapers and other absorbent articles such ascomminuted wood pulp which is generally referred to as airfelt. Examplesof other suitable absorbent materials include creped cellulose wadding;chemically stiffened, modified or cross-linked cellulosic fibers; tissueincluding tissue wraps and tissue laminates; absorbent foams; absorbentsponges; superabsorbent polymers; absorbent gelling materials; or anyequivalent material or combinations of materials.

[0062] The topsheet 54 is preferably compliant, soft feeling, andnon-irritating to the wearer's skin. Further, the topsheet 54 ispreferably liquid pervious permitting liquids (e.g., urine) to readilypenetrate through its thickness. A suitable topsheet 54 may bemanufactured from a wide range of materials such as woven and nonwovenmaterials; polymeric materials such as apertured formed thermoplasticfilms, apertured plastic films, and hydroformed thermoplastic films;porous foams; reticulated foams; reticulated thermoplastic films; andthermoplastic scrims. Suitable woven and nonwoven materials can becomprised of natural fibers (e.g., wood or cotton fibers), syntheticfibers (e.g., polymeric fibers such as polyester, polypropylene, orpolyethylene fibers) or from a combination of natural and syntheticfibers. The topsheet 54 can be rendered hydrophilic by treating it witha hydrophilic finishing oil or a surfactant.

[0063] The absorbent core 28 is preferably joined to the backsheet 52and the topsheet 54 by attachment means (not shown) such as those knownin the art.

[0064] The pull-on diaper 20 can include other features which arepreferably used in disposable pull-on diapers known in the art. Forexample, the pull-on diaper 20 preferably includes elasticallyextensible side panels 56 to ensure a comfortable and contouring fit ofthe pull-on diaper 50 to the wearer. The side panels 56 are joined atseams to form the waist opening 63 and the leg openings 62. The pull-ondiaper 20 preferably further includes leg elastics 58 and waist elasticregion 60 to enhance the fits around the legs and waist openings 62 and63 of the wearer. Preferred leg elastics designs as well as leg cuffdesigns are disclosed in, for example, U.S. Pat. No. 4,695,278 issued toLawson on Sep. 22, 1987; and U.S. Pat. No. 4,795,454 issued to Dragoo onJan. 3, 1989.

[0065] D. Printing Apparatus and Manufacturing Process

[0066]FIG. 4 is a simplified block diagram of a printing andmanufacturing apparatus for disposable absorbent articles. Referring toFIG. 4, the printing apparatus includes a central controller 31, agraphic memory 32, a printer 33, and a dryer 34. The controller 31controls the graphic memory 32, the printer 33, and the dryer 34 forprinting graphics.

[0067] The graphic memory 32 stores necessary graphic data for thegraphics G1-Gn (n is greater than 2). The controller 31 selects thegraphic data stored in the graphic memory 32 and produces graphicsignals Gs. The printer 34 prints the graphics G1-Gn on a sheet material(or a backsheet material) 41 based on the graphic signals Gs. The dryer34 dries the ink printed on the sheet material 41 to fix the inkthereon.

[0068] The controller 31 is preferably constituted by a computer. Anycomputer known in the computer industry can be used. Preferably, amicrocomputer which has an ability (or software) for image dataprocessing is employed. A preferred controller is available from ScitexDigital Printing, Dayton, Ohio, USA, under the trade name “SystemController 220”.

[0069] The graphic memory 32 is preferably constituted by a memorydevice. Any memory device known in the computer industry can be used.Preferably, an image memory device which has a large memory capacity isemployed.

[0070] Any printer known in the printer industry which can printgraphics based on graphic data stored in a memory device can be used asthe printer 34. Preferred printers include Aprion DPS 65 Ink-jetprinters, Indigo Webstream Digital Offset printers, and Scitex DigitalInkjet printers. Ink jet printers are preferably employed as the printer34 since the ink jet printers are suitable for printing a variety ofgraphics based on graphic data supplied thereto. A typically preferredink jet printer includes four printer heads which eject inks of fourbasic colors, i.e., cyan, magenta, yellow and black. Although thegraphics G1-Gn can be drawn by a single color, they are preferably drawnby multi-colors using these four colors. A preferred ink jet printer isavailable from Scitex Digital Printing, Dayton, Ohio, USA, under thetrade name “VersaMark” and “Dijit”. Another preferred ink jet printer isavailable from Videojet Technologies, Ill., USA, under the trade name“PrintPro”. Yet another preferred ink jet printer is available fromAprion, under the trade name “Aprion DPS 65”.

[0071] Any ink known in the printing industry can be used. A preferredink is available from Scitex Digital Printers, Dayton, Ohio, USA, underthe trade name “Scitex Versapure”.

[0072] Any dryer known in the art can be used as the dryer 34.

[0073] In the embodiment shown in FIG. 4, a sheet material 41 issupplied from a stock roll (not shown in Figs.) which contains the sheetmaterial 41 wound up. Similarly, a sheet material 42 is also suppliedfrom a stock roll (not shown in Figs.) which contains the sheet material42 wound up.

[0074]FIG. 5 is a flow chart which shows a process for printing thegraphics G1-Gn on a sheet material 41. The printing process is nowexplained by referring to FIGS. 4 and 5. In this embodiment, the sheetmaterial 41 is the backsheet material. However, the sheet material canbe any one of the other component materials of the absorbent article.Thus, the sheet material 41 can be selected from the group consisting ofa backsheet material, a topsheet material, an acquisition layermaterial, an absorbent core material, and a landing zone material and/ora fastening tape material for waist-fastening means.

[0075] In Step 301, necessary graphic data for printing the graphicsG1-Gn (which are different from each other) is preliminarily producedand stored in the graphic memory 32 in advance.

[0076] In Step 302, one graphic data which is used for printing the j-thgraphic Gj (j: from 1 to n) is selected from the graphic memory 32. In apreferred embodiment, Step 302 includes a step of selecting graphic datastored in the graphic memory 32 in accordance with a predeterminedorder, as already described hereinbefore. Thus, the predetermined orderpreferably includes an order illustrating story, an order for dailyactivity, an order for educational training, a sequential indicationmeans, an order of usage instruction, an order of how to take care ofbabies, and an order of sales promotion.

[0077] Alternatively, Step 302 may include a step of randomly selectinggraphic data stored in the graphic memory 32.

[0078] In Step 303, the graphic Gj is printed by the printer 33 on thesheet material 41 based on the selected graphic data.

[0079] In Step 304, the number of the graphic Gj is checked, and Steps302 and 303 are repeated so that all of the graphics G1-Gn are printedon the sheet material 41.

[0080] In a further succeeding step (not shown in FIG. 5), Steps 301-304are preferably repeated so that the n graphics G1-Gn are periodicallyprinted in each printing frame PF on the sheet material 41. Herein,“printing frame” is defined as a period which contains the n graphicsG1-Gn. Thus, each printing frame PF contains the n graphics G1-Gn in thesame order.

[0081] Although the embodiment shown in FIG. 4 is an online printingprocess (i.e., the printing process is a part of a diaper manufactureprocess), the printing process can be an offline one. In the offlineprinting process, it ends at a winding step for winding the printedsheet material 41 up. In a succeeding diaper manufacture process, thewound sheet member is supplied thereto.

[0082] In the embodiment shown in FIG. 4, the backsheet material 41 isjoined with other component materials, i.e., a topsheet material 42 anddiscrete absorbent core members (or materials) 43 to produce absorbentarticles 201-20 n which are connected through the backsheet material 41and the topsheet material 42. The connected absorbent articles 201-20 nwill be separated by a cutting equipment (not shown in FIG. 4) toproduce individual absorbent articles (not shown in FIG. 4).

[0083] The apparatus further includes frame detector means which detectsa printing frame PF. The frame detector means repeatedly detectsprinting frames PF each including n absorbent articles 201-20 n. Thoseabsorbent articles 201-20 n will be packed in one common package.

[0084] In the embodiment shown in FIG. 4, two frame detectors 35 and 36are provided. These two frame detectors 35 and 36 are preferably locatedalong the machine direction MD with an interval (or distance) which isabout equal to the total length of the n absorbent articles 201-20 n inthe machine direction MD. Each of the frame detectors 35 and 36preferably includes an image sensor (not shown in FIG. 4) which detectsa framing mark (not shown in FIG. 4) which is included in at least apart of the graphics G1-Gn (in one frame). Thus, the sheet material 41has a plurality of framing marks which define the printing frames PF.

[0085] Alternatively, the frame detector means can be constituted by oneframe detector (not shown in FIG. 4) which detects the framing marks. Inthat case, the central controller 31 monitors the number of the framingmarks detected by the frame detector and identifies the printing framePF when the number becomes n.

[0086] The framing mark can be any mark known in the art. The framingmark can be either visible or invisible as long as the frame detectors35 and 36 can detect it. Preferably, the framing mark is printed whenthe graphics G1-Gn are printed on the sheet material 41, i.e., theframing mark is printed on the sheet material 41 together with thegraphics G1-Gn.

[0087] The visible mark can be printed by one (or more) of the same inkswhich is used for printing the graphics G1-Gn. If the invisible mark isused, an invisible ink such as an ultra-violet detectable ink or a nearinfra-red detectable ink needs to be prepared separately from the inksfor the graphics G1-Gn.

[0088]FIG. 6 is a flow chart which shows a process for packing the nabsorbent articles 201-20 n into one package. The packing process is nowexplained by referring to FIGS. 4 and 6.

[0089] In Step 401, the sheet material 41 which has a plurality ofprinting frames PF sequentially disposed along the machine direction MD.Each printing frame PF includes n graphics G1-Gn printed sequentially inthe machine direction MD.

[0090] In Step 402, the sheet material 41 is incorporated with othercomponent materials 42 and 43 to form the n absorbent articles 201-20 nin the machine direction MD.

[0091] In Step 403, the detecting means (e.g., the detectors 35 and 36)detects the printing frame PF in the sheet material 41. This detectionis preferably performed by detecting at least one of the framing markswhich have been printed in the sheet material 41.

[0092] In Step 404, the n absorbent articles 201-20 n which are withinthe detected printing frame PF are transported to a packaging stage (notshown in Figs).

[0093] In Step 405, the n transported absorbent articles 201-20 n arepacked in one common package such as the one 500 shown in FIG. 1. Afterthe n absorbent articles 201-20 n in one printing frame are packed inthe package, the process returns to Step 401 for packing the succeedingabsorbent articles 201-20 n in the next printing frame. (Steps 401-405will be repeated.)

[0094] It is understood that the examples and embodiments describedherein are for illustrative purpose only and that various modificationsor changes will be suggested to one skilled in the art without departingfrom the scope of the present invention.

What is claimed is:
 1. An absorbent product comprising a package and atleast n absorbent articles contained in the package, wherein n isgreater than 10, each of the absorbent articles having a body contactingsurface and a garment contacting surface opposing the body contactingsurface, each of the absorbent articles comprising: a component materialdisposed between the body contacting surface and the garment contactingsurface, the component material having a printed graphic which is seenthrough either the body contacting surface or the garment contactingsurface; wherein the n graphics of the n absorbent articles aredifferent from each other and have a predetermined association.
 2. Theabsorbent product of claim 1, wherein the predetermined associationincludes a predetermined order, and the n absorbent articles are stackedin the package in accordance with the predetermined order.
 3. Theabsorbent product of claim 1, wherein the predetermined associationincludes a common theme, and the n absorbent articles are stacked in thepackage in a randomly selected order.
 4. The absorbent product of claim2, wherein the predetermined order includes an order illustrating story,an order for daily activity, an order for educational training, asequential indication means, an order of usage instruction, an orderillustrating child care tips, and an order of sales promotion.
 5. Theabsorbent product of claim 4, wherein the story includes a children'sstory, and a cartoon story.
 6. The absorbent product of claim 4, whereinthe daily activities includes eating foods, wearing (or changing) acloth, taking a bath, a toilet activity, making an object, cooking afood, sleeping, and growing a plant.
 7. The absorbent product of claim4, wherein the educational training includes puzzles or quizzes onmathematics, characters, shapes of goods, combinations of colors, andpattern recognition for intelligence development.
 8. The absorbentproduct of claim 4, wherein the sequential indication means includes asequential symbol (e.g., numbers and letters) for indicating remainingabsorbent articles.
 9. The absorbent product of claim 3, wherein thecommon theme includes cartoon characters, transportation means, animals,fruits, vegetables, plants, and seasonal themes.
 10. The method of claim1, wherein the component material is selected from the group consistingof a backsheet, a topsheet, an acquisition layer, an absorbent core, anda landing zone for waist-fastening means.
 11. The absorbent product ofclaim 1, wherein n is selected from 11 to
 120. 12. A method of printinga graphic on a sheet material which will become a component material forabsorbent articles, the method comprising the steps of: (a) storinggraphic data in a graphic memory for printing n graphics, n beinggreater than 2; (b) selecting graphic data stored in the graphic memory;(c) printing a graphic based on the selected graphic data by an ink jeton the sheet material; and (d) repeating the steps (b) and (c) so thatthe n graphics are printed on the sheet material.
 13. The method ofclaim 12, wherein the step (b) includes a step of selecting graphic datastored in the graphic memory in accordance with a predeterminedassociation.
 14. The method of claim 12, wherein the step (b) includes astep of randomly selecting graphic data stored in the graphic memory.15. The method of claim 12, further comprises a step of (e) repeatingthe steps of (b)-(d) so that the n graphics are periodically printed ineach frame on the sheet material.
 16. The method of claim 12, whereinthe n graphics are different from each other.
 17. The method of claim12, wherein the predetermined order includes an order illustratingstory, an order for daily activity, an order for educational training, asequential indication means, an order of usage instruction, an order ofhow to take care of babies, and an order of sales promotion.
 18. Themethod of claim 12, wherein the sheet material is selected from thegroup consisting of a backsheet material, a topsheet material, anacquisition layer material, an absorbent core material, and a landingzone material for waist-fastening means.
 19. A method of producing anabsorbent product comprising a package and at least n absorbent articlescontained in the package, wherein n is greater than 10, the methodcomprising the steps of: (a) supplying a sheet material having aplurality of printing frames sequentially disposed along the machinedirection, each printing frame including n graphics printed sequentiallyin the machine direction; (b) incorporating other component materialswith the sheet material to form n absorbent articles in the machinedirection, each absorbent article having a corresponding graphic of then graphics; (c) detecting the printing frame in the sheet material; (d)transporting the absorbent articles which are within the detectedprinting frame; and (e) packing the transported absorbent articles intoone package.
 20. The method of claim 19, wherein the sheet material hasa plurality of framing marks which define the printing frames, and thestep (c) includes a step of detecting at least one of the framing marks.21. The method of claim 19, wherein the sheet material is selected fromthe group consisting of a backsheet material, a topsheet material, anacquisition layer material, an absorbent core material, and a landingzone material for waist-fastening means.